Andres Villada

Engineering Consultant | Ph.D. Mechanical Engineer | Finite Element Analysis & Materials Expert

About

Mechanical and Materials Engineer with experience in product development, custom testing, material characterization, Finite Element Modeling, and failure analysis. Received a PhD from CU Boulder, specializing in the mechanics of materials and providing innovation in soft robots, flexible electronics, and sleep tracking biosensors.

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Education

University of Colorado Boulder CO

Ph.D. and M.S. in Mechanical Engineering / 2020

Brown University Providence RI

B.S. in Physics / 2014

Experience

Freelance

ENGINEERING CONSULTANT / October, 2024October

Conduct freelance Finite Element Analysis and materials consulting specializing in stress mechanics fatigue and failure analysis. Perform custom stress impact and structural prototype Finite Element Modeling for startups and local clients. Advise clients regarding material choices for product manufacturing performance and safety standards.

Exponent

SENIOR ASSOCIATE / April, 2021October, 2024

Conducted failure analysis consulting across various engineering disciplines focusing on impact fatigue safety and stress testing. Utilized solid mechanics Finite Element Analysis and material testing to determine sources of failure. Performed stress analysis and dropshockfatigue testing using custom experimental setups and computer models. Performed material inspection and characterization for medical devices and consumer electronics. Planned and executed testing protocols rapid prototyping and root cause analysis to validate performance optimize design. Provided written testimony for intellectual property and international arbitration cases. Managed and budgeted 4M project analyzing injury biomechanics related to augmented reality headsets. Led multi-disciplinary team and optimized standard operating procedures effectively doubling productivity. Presented results and potential improvements to clients meeting ISO-9001 Quality Management System requirements.

Earable

MATERIALS ENGINEER / February, 2018April, 2021

Designed and manufactured a wearable flexible electronic biosensor and sleep staging system for mass market. Developed proprietary bio-inspired flexible conductive electrodes to penetrate hair and effectively detect biosignals from scalp enhancing device performance and reducing costs by 90% compared to existing materials. Created 3D CAD models of device prototypes and performed Finite Element testing of performance metrics. Performed stress analysis and implemented engineering design principles to design devices to optimize user experience. Secured 20000+ in grants from University of Colorado Boulder advancing research from concept to commercialization. Collaborated with an international team to facilitate mass manufacturing of the Earable Frenz headband.

Xiao Soft Matter Mechanics Research Group, University of Colorado Boulder

RESEARCH ASSISTANT / August, 2015August, 2020

Designed and manufactured flexible biocompatible electronic devices using smart materials like shape-memory polymers. Developed self-folding thin-film multilayer structures for deployable soft robots. Self-healing and color-changing soft skin for manufacturing robots. Surface patterning using buckling and wrinkling of smart material multilayers. 2D to 3D self-folding origami and kirigami smart systems for use in packaging and other applications. Modeled devices and experiments using 3D CAD software. Correlated experimental results with nonlinear Finite Element Models to explore thermomechanical behavior. Innovated curing techniques to enhance shape molding and adhesion between shape-memory polymers and substrates.

Gaitskell Particle Astrophysics Group, Brown University

RESEARCH ASSISTANT / August, 2012June, 2014

Designed assembled and tested cryogenic photomultiplier tube (PMT) test box for Large Underground Xenon (LUX) dark matter detection experiment. Tested PMT performance in cryogenic test box using an oscilloscope Python and MATLAB for data acquisition and analysis. Maintained ISO 5 clean room for PMT storage.

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